WO2025038501A1

WO2025038501A1 - Cyclone separation vessel

Info

Publication number: WO2025038501A1
Application number: PCT/US2024/041844
Authority: WO
Inventors: Rick Wendell Bajema; Shawn Michael MILAN; Jonathan Daniel KAYLOR; Stephen Christopher HORN; Kim GAP
Original assignee: Heat and Control Inc
Current assignee: Heat and Control Inc
Priority date: 2023-08-13
Filing date: 2024-08-10
Publication date: 2025-02-20
Anticipated expiration: 2026-02-13

Abstract

A cyclone separation vessel having an upper bulkhead, a lower bulkhead, an inlet chamber therebetween, and a plurality of cyclonettes supported within the vessel, each cyclonette having a fluid discharge nipple at a top end disposed above the upper bulkhead, a lower end disposed below the lower bulkhead through which solids are discharged and at least one intake port intermediate the upper bulkhead and the lower bulkhead. The vessel further includes an inlet chamber disposed intermediate an upper bulkhead and a lower bulkhead, and a fluid discharge chamber intermediate the upper bulkhead and a cover.

Description

CYCLONE SEPARATION VESSEL

BACKGROUND

Statement of Related Applications

[0001] This application depends from and claims priority to U.S. provisional utility application serial no. 63/532,406 filed on August 13, 2023.

Field of the Invention

[0002] The present invention relates to a vessel for separating two materials having different densities, such as, but not limited to, solid particles entrained in a stream of fluid, using a plurality of cyclonettes supported within the vessel. The present invention relates to a vessel having a plurality of cyclonettes each of which receives and separates a more dense material, such as a solid, a liquid or a gas, from a less dense material, such as a solid, a liquid or a gas.

Background of the Related Art

[0003] Many processes result in a stream of fluid with entrained solids. The fluid may require disposal or it may be reused. The solid particulates in the stream of fluid must often be removed in order to enable efficient disposal or reuse. Separation of particulates from a stream of fluid may involve the use of cyclonic separation, which relies on the introduction of the stream of fluid with entrained solids, or a portion of a stream of fluid with entrained solids, into a generally cylindrical body in a manner that causes the fluid within the body to spin. More dense particulate matter will move the interior wall of the body and less dense fluid will be displaced towards a center axis of the body. The more dense particulate matter will also sink as it accumulates along the interior wall and discharged from the body through a lower end of the body, while the less dense fluid will be displaced upwardly and discharged through an upper end of the body. Where many such bodies are arranged in an array, the body, with the upper end and lower end, are referred to as cyclonettes, and each cyclonette operates in parallel with the others to separate the solid particulates from the fluid.

BRIEF SUMMARY

[0004] The present invention provides a solids / fluid cyclone separator vessel for separating particulate solids from a stream of fluid. This vessel can be used to remove solids from a stream of fluid to enable recycling or reuse of the fluid or disposal of the fluid without complications caused by the entrained solids.

[0005] One embodiment of the solids / fluid separator vessel of the present invention includes an upper bulkhead that is generally planar, the upper bulkhead having a plurality of apertures arranged in a trapezoidal array which may, in one embodiment, consist of rows and columns, and a lower bulkhead that is generally planar and spaced apart from the upper bulkhead, the lower bulkhead having a corresponding plurality of apertures also arranged in a trapezoidal array, which may also consist of rows and columns. Each of the apertures of the plurality of apertures of the lower bulkhead is aligned with a corresponding aperture of the plurality of apertures in the upper bulkhead. The embodiment of the solids / fluid separator vessel may further include an inlet chamber disposed intermediate the upper bulkhead and the lower bulkhead, the inlet chamber being surrounded by an inlet chamber enclosure wall having a trapezoidal perimeter. Above the upper bulkhead is a cover having a cover flange with a trapezoidal shape to sealably engage a wall flange disposed on the inlet chamber enclosure wall, the cover having a fluid discharge port. The inlet chamber enclosure wall includes an inlet feed port through which a stream of fluid with entrained solids may enter the inlet chamber of the vessel. The embodiment of the solids / fluid separation vessel may further include a fluid discharge chamber disposed intermediate the upper bulkhead and the cover of the vessel that sealably engages the upper bulkhead, the cover having a fluid discharge port through which fluid is discharged from the vessel. [0006] The embodiment of the solids / fluid separation vessel further includes a plurality of cyclonettes corresponding in number to the plurality of apertures in the upper bulkhead and to the plurality of apertures in the lower bulkhead. Each of the plurality of cyclonettes includes a body having at least one intake port through which a stream of fluid with entrained solids enters the body, an overflow nipple, which is connected within the body of the cyclonette to a fluid discharge conduit, the overflow nipple being disposed at a top end through which fluid from the body is discharged into the fluid discharge chamber, a lower end through which solids from the body are discharged.

[0007]

Each cyclonette sealably engages one of the plurality of apertures of the upper bulkhead intermediate the at least one intake port and the fluid nipple of the cyclonette, and each cyclonette also sealably engages one of the plurality of aligned apertures in the lower bulkhead intermediate the at least one intake port and the lower end of the cyclonette. This arrangement provides a plurality of rows of cyclonettes and a plurality of columns of cyclonettes, each row and each column being within the trapezoidal array. As a result, each body of each cyclonette is within the trapezoidal perimeter shape of the flange of the inlet chamber enclosure wall and each upper end of each cyclonette is within the trapezoidal perimeter of the cover.

[0008] Returning to the lower ends of the plurality of cyclonettes, the lower end of each of the plurality of cyclonettes may be, in one embodiment, coupled to one of a plurality of solids accumulator pipes, and each of the plurality of solids accumulator pipes is fluidically coupled to the lower ends of a plurality, such as a column, of cyclonettes. In such an embodiment, each of the plurality of solids accumulator pipes is disposed intermediate the lower ends of a plurality (such as, for example, a column having a plurality) of cyclonettes and a solids discharge port through which solids separated from fluid in the plurality of cyclonettes are discharged from the vessel. Alternately, the lower ends of the plurality of cylonettes may be disposed within the vessel to discharge to a solids discharge chamber of the vessel, the solids discharge chamber having a discharge conduit that delivers the solids to the solids discharge port. Both of these approaches enables the control of the rate at which solids are discharged from the embodiment of the vessel to be isolated and controlled. Another alternative is to simply dispose the lower ends of the plurality of cyclonettes to discharge to the environment surrounding the embodiment of the vessel.

[0009] In one embodiment, each of the plurality of cyclonettes are supported within aligned apertures in the upper and lower bulkheads and are sealably engaged by the apertures. Each row of cyclonettes, and each row of apertures in the upper bulkhead and each row of apertures in the lower bulkhead, are generally parallel to a long base of the trapezoidal perimeter and generally parallel to a short base of the trapezoidal perimeter. One row of the trapezoidal array in which the apertures of the upper and lower bulkheads and the cyclonettes supported therein is proximal to and generally parallel to the long base of the trapezoidal perimeter surrounding the trapezoidal array and form the long base of the trapezoidal array, and one row of the trapezoidal array in which the apertures of the upper and lower bulkheads and the cyclonettes supported therein are supported is proximal to and parallel to the short base of the trapezoidal perimeter surrounding the trapezoidal array and form the short base of the trapezoidal array. Each cyclonette has at least one inlet. In a preferred embodiment of the solids / fluid separator vessel of the present invention, each cyclonette has a pair of inlets, one opposite from the other, and both shaped to direct a portion of the stream of fluid with entrained solids entering the inlet chamber of the vessel into the body of the cyclonette in a direction that is along an interior wall of the cyclonette. This feature causes the fluid within the body to spin and to thereby separate the denser solids component from the less dense fluid component. Naturally, where a cyclonette includes two inlets, the inlets complement each other; that is, they are shaped to produce spin in the same direction within the body for optimal spinning and separation.

[0010] The inlet feed port of the solids / fluid cyclone separator vessel is connectable to a source of a stream of fluid with entrained solids. This stream of fluid with entrained solids may be the off-product or the waste stream from an industrial or food processing system. The solids component may consist of soft solids, such as from processed foods, or harder materials, such as particulate stone, sand, metal, etc. The fluid component may be water or some other fluid or gas. The separation of the solid component from the fluid component requires that the density of the solid component be greater than the density of the fluid. The size and shape of the cyclonettes may be determined by the type and physical characteristics of the solid component and the density and/or viscosity of the fluid component, among other factors.

[0011] One embodiment of the solids / fluid separator vessel of the present invention further comprises a shelf disposed within the inlet chamber, the shelf having a proximal edge proximal to the inlet port in the inlet chamber enclosure and also to the long base of the trapezoidal perimeter, and a distal edge proximal to the short base of the trapezoidal perimeter. In one embodiment, the distal edge of the shelf extends only to the penultimate row of the trapezoidal array or, alternately, in other embodiments, only to the antepenultimate row of the trapezoidal array. The shelf is supported intermediate the lower bulkhead and the upper bulkhead, and proximal to and parallel to the lower bulkhead. The shelf includes a plurality of apertures therein, each aperture being aligned with corresponding aligned apertures in the upper and lower bulkheads. The shelf separates the incoming stream of fluid with entrained solids emerging from the inlet feed port into an upper stream and a lower stream. The upper stream is directed to the intake ports of the plurality of cyclonettes that penetrate the shelf, and the lower stream is isolated by the shelf from the inlets of those cyclonettes that penetrate the shelf. The shelf enables the lower stream to flow beyond the plurality of rows of cyclonettes that penetrate the shelf and to thereby provide sufficient flow to the cyclonettes in the distal row of cyclonettes or, alternately, to the distal row of cyclonettes and the adjacent row of cyclonettes, to prevent unwanted imbalance in the utilization of capacity of the cyclonettes distributed within the trapezoidal array. The shelf also extends the high velocity inlet flow to surface of the lower bulkhead furtherest from the inlet to reduce the potential of solids to settle on the lower bulkhead and improve the self-cleaning attributes of the inlet chamber of the vessel.

[0012] One embodiment of the solids / fluid cyclone separator vessel of the present invention further includes an inlet flow distribution manifold disposed intermediate the inlet feed port, through which a stream of fluid with entrained solids enters the inlet chamber of the vessel, and the inlet chamber of the vessel. The inlet flow distribution manifold distributes the incoming stream of fluid with entrained solids evenly across the long base of the trapezoidal perimeter to promote evenly divided flow among the plurality of columns of cyclonettes of the trapezoidal array. [0013] One embodiment of the solids / fluid cyclone separator vessel of the present invention further includes a plurality of pillars disposed intermediate the upper bulkhead and the lower bulkhead to secure the upper bulkhead to the lower bulkhead and to thereby stabilize the structures that support the cyclonettes in the trapezoidal array. The embodiment may further comprise a plurality of support legs connected to the vessel to support the vessel above a floor. This design approach enables the vessel size and number of cyclonettes (numbers of rows and columns) to be scaled down or up to very large numbers without changing the thicknesses of the upper and lower bulkheads.

[0014] Embodiments of the solids / fluid cyclone separator vessel of the present invention are described and disclosed herein as being used to separate one material from the other where the two materials to be separated have different densities. This differential density enables the use of spinning the solution, comprised of the two materials of different densities, within a cyclonette or a plurality of cyclonettes, to displace the more dense material, such as, for example, solid particulate matter, radially outwardly from an axis of the cyclonette towards the interior wall of the cyclonette and by simultaneously displacing the less dense material, such as, for example, water or some other fluid, radially inwardly towards the axis of the cyclonette. Embodiments of the solids / fluid cyclone separator can, therefore, be used to separate a more dense gas from a less dense gas, to separate a more dense liquid (fluid) from a less dense gas (fluid), and to separate a more dense solid from a less dense liquid, which is the application used as an example in the discussion herein above and below. It will be understood that the sizing and dimensions of, for example, but not by way of limitation, the cyclonettes, the inlet chamber, the inlet flow port, the fluid discharge port, etc., may be optimized for the application for which the embodiment is to be used. That is, an embodiment of the present invention that is intended to be used to separate a fluid that is a liquid having a lower density from suspended or entrained solid particles that have a greater density may also be used to separate a liquid having a lower density from a liquid having a greater density or it could be used to separate a gas having a lower density from a liquid having a greater density.

[0015] The convergence of the inlet chamber of an embodiments of the solids / fluid cyclone separation vessel of the present invention, from the proximal row of cyclonettes to the distal row of cyclonettes, maintains a more constant flow velocity between the cyclonettes and/or between adjacent columns of cyclonettes from the inlet manifold to the distal row. Otherwise, the consumption of the inlet flow entering the inlet chamber at the inlet flow port by the rows of cyclonettes proximal to the inlet flow port would result in the reduction of flow velocity at the rows of cyclonettes distal to the inlet flow port (such as, for example, the distal row, the penultimate row, and the antepenultimate row). Factors such as, but not limited to, the shape of the cyclonette body and flow rate of each individual cyclonette are to be considered. Cyclonettes with narrower bottoms than tops in the infeed chamber are preferred to keep the flow velocities higher on the top surface of the bottom bulkhead to prevent accumulation of solids.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0016] FIG. 1 is an elevation view of a cyclonette used to separate particulates from a stream of fluid.

[0017] FIG. 2 is a perspective view of an embodiment of a solids / fluid cyclone separator vessel of the present invention.

[0018] FIG. 3 is a plan view of the solids / fluid cyclone separator vessel of FIG. 2 with the cover removed to reveal the fluid discharge chamber and the upper ends of the plurality of cyclonettes that protrude through apertures in the upper bulkhead.

[0019] FIG. 4 is a side elevation sectional view of the solids / fluid cyclone separator vessel of FIG. 3.

[0020] FIG. 5 is a bottom plan view of the solids / fluid cyclone separator vessel of FIG. 2.

[0021] FIG. 6 is a perspective sectional view of the solids / fluid cyclone separator vessel of FIG. 2 with the cyclonettes, the upper bulkhead, the inlet chamber enclosure wall and the cover removed and two columns of cyclonettes removed to reveal the positioning of the pillars. [0022] FIG. 7 is a perspective sectioned view of the solids / fluid cyclone separator of

FIG. 2.

[0023] FIG. 8 is an enlarged view of the portion of the vessel 10 of FIG. 7 showing the gate, the lower bulkhead, the proximal end of the shelf and one of the cyclonettes of the proximal row of cyclonettes.

[0024] FIG. 9 is an enlarged view of the portion of the vessel 10 of FIG. 7 showing the distal end of the shelf, the lower bulkhead and one of the cyclonettes of the distal row of cyclonettes.

[0025] FIG. 10 is an enlarged sectioned plan view of the cyclonette of FIG. 1 illustrating the use of a radially outwardly protruding tab disposed on the lower tapered portion of the cyclonette, the tab being received into a corresponding recess in the aperture of the lower bulkhead in which the cyclonette 60 is supported to secure the cyclonette against rotation and to strategically orient the one or more inlets for optimal fluid flow into the body.

DETAILED DESCRIPTION

[0026] FIG. 1 is an elevation view of a cyclonette 60 used to separate particulates from a stream of fluid, liquids of different density or gas bubbles from liquid. The cyclonette 60 of FIG. 1 includes an upper end 62 and a lower end 64, a body 68 intermediate the upper end 62 and the lower end 64, a tapered lower portion 67 intermediate the body 68 and the lower end 64, and a pair of opposed inlets 61A and 61B disposed intermediate the body 68 and the upper end 66. The cyclonette 60 of FIG. 1 further includes a fluid nipple 65 at the upper end 62 through which fluid is discharged from the interior spin chamber 69 of the body 68 as indicated by arrow 66 and a solids nipple 71 at the lower end 64 through which solids are discharged from the interior spin chamber 69 as indicated by arrow 72. The solids nipple 71 is shown as coupled to a solids accumulator pipe 74. Streams of fluid with entrained solids enter the cyclonette 60 through the inlets 61A and 61B and directed by the inlets 61A and 61B along the interior wall 69A of the spin chamber 69 to impart a spinning movement to the fluid within the spin chamber 69A, causing more dense solids to be displaced radially outwardly away from the axis 75 as they sink toward the lower end 64. The less dense fluid is displaced radially inwardly towards the axis 75 and upwardly towards the upper end 62.

[0027] FIG. 2 is a perspective view of an embodiment of a solids / fluid cyclone separator vessel 10 of the present invention. The vessel 10 of FIG. 2 comprises a cover 12 that has a trapezoidal perimeter including a short base 11 and a long base 13 opposite to and parallel to the short base 11. The vessel 10 further includes a left side 16 and a right side 15 intermediate the short base 11 and the long base 13. The cover 12 further includes a fluid discharge port 17 through which fluid is discharged from the vessel 10. The fluid discharge port 17 of the vessel of FIG. 2 is fitted with a fluid discharge flange 18 for coupling to, for example, a pipe through which the fluid flows in the direction indicated by arrow 23 to another location or to another vessel. The cover 12 of the vessel 10 shown in FIG. 1 surrounds and encloses a fluid discharge chamber (not shown in FIG. 1). The fluid discharge port 17 can be located on any side or the top of the cover 12 as needed to integrate smoothly into the other process plumbing. The embodiment illustrated in the drawings appended hereto includes seven columns and six rows of cyclonettes. Similar logic applies to any combination of rows and columns including, but not limited to, two or more columns and two or more rows.

[0028] The vessel 10 of FIG. 1 further includes an inlet feed port 24 through which a stream of fluid with entrained solids enters the vessel 10. The inlet feed port 24 of the vessel 10 of FIG. 2 is fitted with an inlet feed port flange 21 for coupling the vessel 10 to a pipe through which the stream of fluid with entrained solids is delivered to the vessel 10 in a direction indicated by arrow 22. The inlet feed port 24 introduces fluid into an inlet feed distribution manifold 20 disposed intermediate the inlet feed port 24 and the inlet chamber (not shown) of the vessel 10. The inlet chamber (not shown) is surrounded by an inlet chamber enclosure wall 41 having an inlet chamber enclosure wall flange 19. The edge of an upper bulkhead 30 is shown disposed intermediate the cover flange 14 of the cover 12 and the inlet chamber enclosure wall 41.

[0029] The tapered lower portion 67 of a plurality of cyclonettes 60 can be seen protruding from the inlet chamber, to be shown in more detail in the discussion of the following drawings. The solids nipples 71 at the lower ends 64 of the cyclonettes 60 of the vessel 10 of FIG. 2 are each coupled to one of a plurality of solids accumulator pipes 74. The plurality of solids accumulator pipes 74 carry the solids from the cyclonettes 60 to a solids gathering manifold 77 from which the solids are discharged from the vessel 10 through a solids discharge port 76 in the direction indicated by arrow 79. The solids discharge port 76 of the vessel 10 of FIG. 2 is fitted with a solids discharge flange 78 for coupling the solids discharge port 76 to a pipe that delivers the solids to another location or process. The vessel 10 of FIG. 2 is shown as being supported by a plurality of legs 89.

[0030] FIG. 3 is a plan view of the solids / fluid cyclone separator vessel 10 of FIG. 2 with the cover 12 removed to reveal the fluid discharge chamber 31, the upper ends 62 of the plurality of cyclonettes 60 and the apertures 32 in the upper bulkhead 30 through which the upper ends 62 protrude. The cyclonettes 60 shown in FIG. 3 are arranged within a trapezoidal array 33 having a long base at a proximal row 34 and a short base at a distal row 35. The trapezoidal array 33 of FIG. 3 is comprised of a plurality of rows intermediate the proximal row 34 and the distalmost row 35, and a plurality of columns 36. While the rows of the trapezoidal array 33 of FIG. 3 are generally parallel, the columns 36 are convergent. As a result, the apertures 32 of the proximal row 34 of the trapezoidal array 33 are spaced further apart from each adjacent aperture 32 in that proximal row 34 than the apertures 32 of the distalmost row 35 and the cyclonettes 60 supported within the apertures 32 of the proximal row 34 are spaced further apart from each adjacent cyclonette 32 in that proximal row 34 than the cyclonettes 60 of the distalmost row 35. For example, it will be observed that the convergent columns result in a greater spacing 37 between adjacent apertures 32 in the proximal row 34 and a smaller spacing 38 between adjacent apertures 32 in the distal row 35. As will be illustrated further and discussed in relation to FIG. 7 below, this strategic spacing arrangement promotes the movement of fluid with entrained solids emerging from the inlet feed port 24 and the inlet feed distribution manifold 20 into the inlet chamber 50 that lies underneath the upper bulkhead 30 shown in FIG. 3. FIG. 3 also illustrates the locations in which fasteners 58 may be disposed for securing the upper bulkhead 30 to pillars 40 that are secured to the lower bulkhead 51 (not shown in FIG. 3). [0031] FIG. 4 is a side elevation sectional view of the solids / fluid cyclone separator vessel 10 of FIG. 3 with the section line taken through the middle of the vessel 10 as indicated in FIG. 3. FIG. 4 illustrates the relative positions of the inlet feed port 24 fitted with the inlet feed port flange 21, the inlet feed distribution manifold and the inlet chamber 50 beneath the fluid discharge chamber 31, the inlet chamber 50 being isolated from the fluid discharge chamber 31 by the upper bulkhead 30. The upper end 62 of the cyclonettes 60 protrude through the apertures 32 in the upper bulkhead 30 to dispose the fluid nipples 65 within the fluid discharge chamber 31. The bodies 68 of the cyclonettes 60 are disposed within the inlet chamber 50 intermediate the upper bulkhead 30 and the lower bulkhead 51. The inlet chamber 50 is surrounded by the inlet chamber enclosure wall 41 which provides a trapezoidal perimeter. The cover 12 is secured to the upper bulkhead 30 at its perimeter, and the cover 12 is stabilized with gussets 25 for rigidity and resistance to unwanted deformation due to fluid pressure. The lower tapered portions 67 of the cyclonettes 60 extend downwardly from the lower bulkhead 51 to the solids nipples 71 that is coupled to the solids accumulator pipes 74. Solids discharged from the cyclonettes 60 through the solids nipple 71 are carried by the solids accumulator pipes 71 to the solids gathering manifold 77 from which the solids are discharged from the vessel 10 through the solids discharge port 76. A downcomer 70 extends from each of the solids accumulator pipes 74 to the solids gathering manifold 77. A plurality of legs 89 support the vessel 10 on a floor or other surface. The solids gathering manifolds can be plumbed together in a plurality of ways to facilitate the flow of solids concentrate with attention given to minimize the difference in friction losses between the different nipples.

[0032] FIG. 5 is a bottom plan view of the solids / fluid cyclone separator vessel 10 of FIG. 2. FIG. 5 illustrates the positions of the legs 89, the fluid discharge port 17 fitted with the fluid discharge port flange 18, and the trapezoidal array 33 of cyclonettes 60 where the lower ends 64 of the cyclonettes 60 are coupled to the solids accumulator pipes 74. FIG. 5 shows the solids gathering manifold 77 and the solids discharge port 76 fitted with the solids discharge flange 78. Above the solids discharge port 76 on the vessel 10 is the inlet feed distribution manifold 20. The spacing 37 between adjacent rows of cyclonettes 60 varies due to the convergence of the columns of cyclonettes 60 towards the distal row 35 of cyclonettes 60. [0033] FIG. 6 is a perspective sectional view of the solids / fluid cyclone separator vessel 10 of FIG. 2 with some of the plurality of cyclonettes 60, the upper bulkhead 30, the inlet chamber enclosure wall 41, the cover 12 and two columns of cyclonettes 60 removed to reveal the positioning of pillars 40 disposed within the inlet chamber 50. The pillars 40 provide stabilization of components of the vessel 10 by interconnecting the upper bulkhead 30 to the lower bulkhead 51. FIG. 6 shows a plurality of apertures 52 in the lower bulkhead 51 where some of the cyclonettes 60 have been removed. FIG. 6 shows some of the plurality of cyclonettes 60 supported within occupied apertures 52 of the lower bulkhead 51, those apertures 52 being positioned for alignment with corresponding apertures 32 (not shown) in the upper bulkhead 30 upon installation securing of the upper bulkhead 30 (not shown) to the trapezoidal flange 19 that surrounds the inlet chamber 50. The pillars allow the bulkheads to be made of thinner material and the size of the bundle to be scaled up and down without changing the bulkhead thickness.

[0034] FIG. 6 further illustrates that the removal of the inlet chamber enclosure wall 41 reveals the bodies 68 of the cyclonettes 60 supported within the apertures 52 of the lower bulkhead 51. The bodies 68 are disposed above the lower bulkhead 51 and the lower tapered portions 67 of the cyclonettes 60 are shown disposed below the lower bulkhead 51. FIG. 6 further shows a plurality of fittings 74A on the solids accumulator pipes 74 to facilitate the coupling of the solids nipples 71 to the solids accumulator pipes 74. FIG. 6 shows the positions of the inlets 61A on the upper ends 62 of the cyclonettes 60 proximal to the upper ends 62 of the cyclonettes 60 but below the position of the upper bulkhead 30 (not shown) upon installation of the upper bulkhead 30 onto the flange 19. The pair of inlets 61A and 61B (not shown) are positioned on the cyclonettes 60 to receive fluid with entrained solids from the inlet feed port 24 and the inlet feed distribution manifold 20 and to direct the fluid and solids into the bodies 68 of the cyclonettes 60. The fluid nipples 65 are, upon installation and securing of the upper bulkhead 30 (not shown) to the flange 19, disposed above the upper bulkhead 30 and within the fluid discharge chamber 31.

[0035] FIG. 7 is a perspective sectioned view of the solids / fluid cyclone separator 10 of FIG. 2 after the addition of a shelf 42 disposed within the inlet chamber 50. The shelf 42 includes a proximal edge 43 intermediate the proximal row 34 of the plurality of cyclonettes 60 and the inlet feed distribution manifold 20 and a distal edge 44 disposed intermediate the distalmost row 35 of cyclonettes 60. The shelf 42 is parallel to and proximal to the lower bulkhead 51 to create a lower flow passage 49 between the shelf 42 and the lower bulkhead 51. The shelf 42 includes apertures 48 each of which are aligned with a corresponding aperture 32 in the upper bulkhead 30 and a corresponding aperture 52 in the lower bulkhead 51. The shelf 42 includes a plurality of apertures 48 where some of the cyclonettes 60 penetrate the shelf 42. The apertures 48 of the shelf 42 engage the cyclonettes 60 that penetrate the shelf 42 below the at least one inlet 61A of the engaged cyclonette 60 to prevent unwanted cross-flow between the lower flow passage 49 and the upper flow passage 53, which is the remainder of the inlet chamber

50. Fluid with entrained solids enters the vessel 10 through the inlet feed port 24 that is fitted with the inlet feed port flange 21, passes through the inlet feed distribution manifold 20, then passes through a plurality of gates 45 disposed intermediate the proximal edge 43 of the shelf 42 and the inlet feed distribution manifold 20. The stream of fluid with entrained solids is divided into two stream portions, an upper stream portion that flows intermediate the shelf 42 and the upper bulkhead 30 and a lower stream portion that flows intermediate the shelf 42 and the lower bulkhead 51. The upper stream portion provides fluid with entrained solids to the inlets 61A and 61B of the plurality of cyclonettes 60 that penetrate the shelf 42 at the apertures 48 and the lower stream portion provides fluid with entrained solids to the inlets 61A and 61B of the plurality of cyclonettes 60 that are distal to the distal edge 44 of the shelf 42. The shelf 42, like the trapezoidal perimeter and the trapezoidal array 33 of the plurality of cyclonettes 60 (which is convergent towards the distal row of cyclonettes 60), thereby promotes the efficient distribution of the stream of fluid with entrained solids among the plurality of cyclonettes 60.

[0036] FIG. 8 is an enlarged view of the portion of the vessel 10 of FIG. 7 showing the gates 44, the lower bulkhead 51, the proximal edge 43 of the shelf 42 and one of the proximal row 34 of cyclonettes 60. The “Y” shaped arrow of FIG. 8 illustrates the incoming stream 54 of fluid with entrained solids is divided into two stream portions, an upper stream portion 55 that flows intermediate the shelf 42 and the upper bulkhead 30 and a lower stream portion 56 that flows intermediate the shelf 42 and the lower bulkhead

51. The upper stream portion 55 provides fluid with entrained solids to the inlets 61A and 61B of the plurality of cyclonettes 60 that penetrate the shelf 42 at the apertures 48 and the lower stream portion 56 provides fluid with entrained solids to the inlets 61A and 61B of the remaining cyclonettes 60 that are distal to the distal edge 44 of the shelf 42.

[0037] FIG. 9 is an enlarged view of the portion of the vessel 10 of FIG. 7 showing the distal end 44 of the shelf 42, the lower bulkhead 51 and one of the distalmost row 35 of cyclonettes 60. The lower stream portion 56 is indicated by the arrow as emerging from the lower flow passage 49 adjacent the distal edge 44 of the shelf 42 to supplement the supply of fluid with entrained solids reaching the distalmost row 35 of cyclonettes 60.

[0038] FIG. 10 is an enlarged sectioned plan view of the cyclonette 60 of FIG. 1 illustrating the use of a radially outwardly protruding tab 69 disposed on the lower tapered portion 67 of the cyclonette 60, the tab 69 being received into a corresponding recess in the aperture 52 of the lower bulkhead in which the cyclonette 60 is supported to secure the cyclonette 60 against rotation and to strategically orient the one or more inlets 61A and 61B for optimal fluid flow into the body 68. For example, but not by way of limitation, fluid flow into the body 68 of a cyclonette 60 may be increased by disposing a pair of opposed inlets 61A and 61B (not shown in FIG. 10 - see FIG. 1) proximal to the unobstructed flowpaths between the convergent columns of the trapezoidal array 33. These unobstructed flowpaths may, in some embodiments of the present invention, reside within the spacings 37 (see FIGs. 3 and 5) between convergent rows of the trapezoidal array 33 of cyclonettes 60. The radially outwardly protruding tab 69 on the cyclonette 60 can be aligned with and received into a corresponding recess 59 in the aperture 52 of the lower bulkhead 51 to strategically dispose and retain the inlets 61A and 61B (see FIG. 1) proximal to the flowpaths that lie along the spacings 37.

[0039] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components and/or groups, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.

[0040] The corresponding structures, materials, acts, and equivalents of all means or steps plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but it is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

Claims

CLAIMS What is claimed is:

1 . A cyclone separator vessel, comprising: an upper bulkhead having a plurality of apertures arranged in a convergent array; a lower bulkhead having a plurality of apertures arranged in a convergent array, each of the apertures of the plurality of apertures of the lower bulkhead aligned with a corresponding aperture of the plurality of apertures in the upper bulkhead; an inlet chamber disposed intermediate the upper bulkhead and the lower bulkhead, the inlet chamber being surrounded by an inlet chamber enclosure wall having a convergent perimeter; a cover having a cover flange with a convergent shape to sealably engage the inlet chamber enclosure wall, the cover having a fluid discharge port; an inlet feed port through which a stream of fluid with entrained solids may enter the inlet chamber of the vessel; a fluid discharge chamber disposed intermediate the upper bulkhead and the cover of the vessel that sealably engages the inlet chamber enclosure wall, the cover having a fluid discharge port through which fluid is discharged from the vessel; a plurality of cyclonettes, each having an overflow nipple at a top end through which fluid is discharged into the fluid discharge chamber, a lower end through which solids are discharged, and a body therebetween, at least one intake port through which a portion of the stream of fluid with entrained solids enters the body of the cyclonette, each cyclonette sealably engaging one of the plurality of apertures of the upper bulkhead intermediate the at least one intake port and the overflow nipple of the cyclonette and sealably engaging one of the plurality of apertures in the lower bulkhead intermediate the at least one intake port and the lower end of the cyclonette.

2. The cyclone separator vessel of claim 1, further comprising: a solids discharge port through which solids separated from the stream of fluid with entrained solids is discharged from the vessel; and a plurality of solids accumulator pipes, each solids accumulator pipe being fluidically coupled to the lower ends of at least some of the lower ends of the plurality of cyclonettes and each solids accumulator pipe being disposed intermediate the lower ends of the some of the plurality of cyclonettes and the solids discharge port.

3. The cyclone separator vessel of claim 1, further comprising: a solids discharge chamber to receive solids discharged from the lower end of the plurality of cyclonettes, the solids discharge chamber being in fluid communication with the solids discharge port.

4. The cyclone separator vessel of claim 1, wherein the convergent array is a trapezoidal array.

5. The cyclone separator vessel of claim 1, wherein the convergent perimeter is a trapezoidal perimeter.

6. The cyclone separator vessel of claim 4, wherein the convergent perimeter is a trapezoidal perimeter.

7. The cyclone separator vessel of claim 1, wherein the plurality cyclonettes, the plurality of apertures through the upper bulkhead in which the plurality of cyclonettes are supported, and the plurality of aligned apertures of the lower bulkhead in which the cyclonettes are supported are arranged in a plurality of rows, each row being parallel to a long base of the convergent perimeter to and also to a short base of the convergent perimeter.

8. The cyclone separator vessel of claim 1, wherein the inlet feed port is connectable to a source of a stream of fluid with entrained solids.

9. The cyclone separator vessel of claim 1, further comprising a shelf having a proximal edge and a distal edge, the shelf disposed intermediate the lower bulkhead and the upper bulkhead and supported in a position proximal to and parallel to the lower bulkhead to separate a stream of fluid with entrained solids emerging from the inlet feed port into two separate portions, the shelf having a plurality of apertures to engage the bodies of some of the plurality of cyclonettes intermediate the at least one intake port and the lower end of the cyclonettes; wherein the portion of the stream of fluid with entrained solids emerging from the inlet feed port and passing intermediate the shelf and the lower bulkhead bypasses the bodies of the some of the plurality of cyclonettes proximal to a proximal end of the shelf and is directed to a remainder of the plurality of cyclonettes disposed distal to a distal end of the shelf.

10. The cyclone separator vessel of claim 1, further comprising: an inlet flow distribution manifold disposed intermediate the inlet feed port through which a stream of fluid with entrained solids enters the inlet chamber of the vessel.

11. The cyclone separator vessel of claim 1, further comprising: a plurality of support pillars disposed intermediate the cover and the upper bulkhead to secure the lower bulkhead to the upper bulkhead.

12. The cyclone separator vessel of claim 1, further comprising: a plurality of support legs connected to the vessel to support the vessel above a floor.

13. The cyclone separator vessel of claim 1, wherein the convergent array includes: a plurality of columns, each column extending from a proximal position that is proximal to a long base of the convergent array to a distal position that is proximal a short base of the convergent array; and a plurality of rows, each row extending from leftmost position that is proximal to a first side of the convergent array to a rightmost position that is proximal a second side of the convergent array.

14. The cyclone separator vessel of claim 13, wherein the plurality of columns are convergent; and wherein a row that is proximal to the long base of the trapezoidal array is longer than a row that is proximal to the short base of the convergent array.

15. The cyclone separator vessel of claim 1, wherein each of the plurality of apertures in the upper bulkhead includes a recess; and wherein each of the plurality of cyclonettes includes a radially outwardly protruding tab sized for being received within a recess in one of the plurality of apertures in the upper bulkhead to prevent rotation of the cyclonette supported within the aperture.

16. The cyclone separator vessel of claim 1, wherein each of the plurality of apertures in the lower bulkhead includes a recess; and wherein each of the plurality of cyclonettes includes a radially outwardly protruding tab sized for being received within a recess in one of the plurality of apertures in the lower bulkhead to prevent rotation of the cyclonette supported within the aperture.